US6663422B1

US6663422B1 - Jaw blades and jaw blade couplers for watthour meter socket adapter

Info

Publication number: US6663422B1
Application number: US10/047,722
Authority: US
Inventors: Darrell Robinson; Allen V. Pruehs
Original assignee: Ekstrom Industries Inc
Current assignee: EJ Brooks Co
Priority date: 2002-01-14
Filing date: 2002-01-14
Publication date: 2003-12-16
Anticipated expiration: 2022-01-14

Abstract

A coupler for use in a watthour meter socket adapter mechanically connects a jaw contact and a blade terminal. External conductors are separately attachable to the jaw contact and the blade terminal in one aspect. In another aspect, the coupler is an electrical fuse fixed between the jaw contact and the blade terminal. In another aspect, the coupler isolates the jaw contact from the blade terminal.

Description

BACKGROUND

1. Field of the Invention

The present invention relates, in general, to electrical watthour meters and, specifically, to watthour meter mounting enclosures or socket adapters.

2. Description of the Art

Electrical power is supplied to an individual site or service by external electrical power line conductors located above or below ground. In a conventional arrangement, electrical power line conductors are connected to terminals in a watthour meter socket mounted on a building wall. Electrical load conductors are connected to another set of terminals in the meter socket and extend to the electrical distribution network in the building. A watthour meter is connected to both pairs of terminals in the meter socket to measure the electric power drawn through the load conductors.

Due to the current trend toward the use of plug-in watthour meters, A to S type socket adapters have been devised which convert A-base type bottom connected watthour meter sockets to receive plug-in watthour meters. Another type of socket adapter has been devised which allows the installation of other devices between the watthour meter socket and a plug-in watthour meter.

Such socket adapters employ a generally annular base having a shell joined thereto and extending outward from one side of the base. Jaw contacts are mounted in the shell and base. Each jaw contact has a female jaw portion disposed interiorly within the shell and a male blade terminal connected to the female jaw portion and extending outward through the base for plug-in connection to the terminals in the meter socket housing.

In previous watthour meter socket adapters, the jaw contacts were of two different constructions. In one construction, the jaw contacts have a folded over design formed of a base wall fixedly mounted by a fastener to the shell of the socket adapter and two spaced sidewalls extending therefrom. The outer ends of the sidewalls are folded over inwardly between the sidewalls and terminate in parallel end flanges which slidably receive a blade terminal of a watthour meter. A blade terminal is usually fixedly connected to the base wall of the jaw contact for connection to jaw contact in a meter socket.

In the second construction, the jaw contacts are formed of a generally planar terminal having opposed first and second ends. An angularly bent spring clip is riveted at one end to an intermediate portion of the terminal and extends to a contact edge disposed in separable engagement with the first end of the terminal to form a jaw for receiving the blade terminal of a watthour meter. The spring clip forcibly biases the watthour meter terminal into secure electrical engagement with the terminal. The second end of the blade terminal extends exteriorly from the base of the watthour meter socket adapter for releasable engagement in a socket jaw contact. A cotter pin is inserted through an intermediate aperture in the terminal to fixedly mount the terminal and jaw contact in position in the watthour meter socket adapter.

Other contact configurations, such as a three finger contact shown in the current assignee's prior U.S. Pat. No. 5,853,300, have also been devised.

However, it is believed that further improvements can be made to watthour meter socket adapter jaw contact and blade terminal structure for use in different applications.

SUMMARY

In one aspect of the present invention, the separate three finger potential jaw contact and the separate blade terminal are interconnected in a unitary structure, while remaining electrically isolated from each other by means of a coupler which engages opposed side edges of one jaw contact and one blade terminal.

In one aspect, the coupler is formed of an electrically insulating material and is constructed of a one piece member. A first end portion of the coupler receives the jaw contact and an opposed second end portion receives the blade terminal.

In one aspect, an engagement member is carried on the first portion of the coupler for releasably engaging the jaw contact when the jaw contact is mounted in the first end of the coupler.

In another aspect of the coupler, the coupler is in the form of a one piece body having opposed end portions, a first end portion receiving the jaw contact and a second end portion for receiving the blade terminal.

This aspect of the present coupler is ideally suited for use with a jaw contact having a U-shaped channel portion. The first end portion of the coupler is fixedly mounted within the channel portion in a non-rotatable position. The blade terminal also has a channel-shaped end for receiving the second end portion of the coupler.

In one aspect, the coupler may be formed as an electrical fuse with outwardly extending end tabs which are joinable to the jaw contact and blade terminal.

In another aspect of the present invention, an electrical contact is mountable in a watthour meter socket adapter and has a base, an electrical conductor connector projecting from one end of the base, and three laterally spaced legs projecting from the base to define a jaw contact. Support and wall members extend from the base for forming recesses which receive one edge of the base of the contact to fix the contact in the socket adapter.

The socket adapter and coupler of the present invention uniquely enables separate jaw contacts and blade terminals to be uniquely carried in a one piece unit for ease of assemble and mounting in a socket adapter. The coupler may take many different forms, one allowing the connection of separate, typically large diameter electrical conductors to the jaw contact and the blade terminal. In another aspect, the coupler may take the form of an electrical fuse having end portions electrically connected to the jaw contact and the blade terminal.

BRIEF DESCRIPTION OF THE DRAWING

The various features, advantages and other uses of the present invention will become more apparent by referring to the following detailed description and drawing in which:

FIG. 1 is an exploded, perspective view showing one embodiment of a watthour meter socket adapter according to the present invention;

FIG. 2 is a perspective view of the watthour meter socket adapter shown in FIG. 1, with the dead front shield portion of the shell removed;

FIG. 3 is a partially broken-away, rear, perspective view of the shell of the socket adapter shown in FIG. 1;

FIG. 4 is a partially cross-sectioned, side view of FIGS. 1 and 2;

FIG. 5 is a perspective view of another embodiment of a jaw blade according to the present invention;

FIG. 6 is a partially cross sectioned, perspective view showing the mounting of the jaw blade depicted in FIG. 5 in a watthour meter socket adapter extender housing constructed according to the present invention;

FIG. 7 is a perspective view of another embodiment of a safety shield according to the present invention;

FIG. 8 is an enlarged, partial, perspective view of FIG. 7 showing the jaw contact safety shield mounting aperture and latch projection;

FIG. 9 is an enlarged, partial, perspective view of FIG. 7 showing the interlocking of the safety shield with the latch projection depicted in FIG. 8;

FIG. 10 is a perspective view of yet another embodiment of a safety shield according to present invention;

FIG. 11 is a partial, enlarged, perspective view showing the interlocking of the safety shield of FIG. 10 with the socket adapter housing depicted in FIG. 6;

FIG. 12 is a perspective view of another embodiment of a safety shield according to the present invention;

FIG. 13 is a partial, enlarged, perspective view showing the interlocking of the safety shield of FIG. 12 in the socket adapter depicted in FIG. 6;

FIG. 14 is an enlarged, partial, perspective view showing a feature of the safety shields shown in FIGS. 7, 10 and 12;

FIG. 15 is a perspective view of another embodiment of a safety shield according to the present invention;

FIG. 16 is a rear perspective view of a safety shield and a surge conductor shown in FIG. 15;

FIG. 17 is a partial, lateral, cross-sectional view showing the mounting of the safety shield and one surge ground conductor of FIG. 16 in the socket adapter shown in FIG. 15;

FIG. 18 is an enlarged, partial, perspective view showing the interconnection of the spring fingers on the surge ground conductor with the safety shield shown in FIG. 15;

FIG. 19 is a plan view showing one embodiment of circuit board mounts in a socket adapter;

FIG. 20A is a front elevational view of another embodiment of a watthour meter socket adapter housing according to the present invention with circuit board mounting means;

FIG. 20B is a cross sectional view showing a power connection between a blade terminal and a circuit board mounted in the socket adapter of FIG. 20A;

FIG. 21A is a perspective view of a printed circuit board mountable in the socket adapter according to the present invention;

FIG. 21B is a perspective view of a modified printed circuit board according to the present invention;

FIG. 21C is a perspective view of another embodiment of a printed circuit board according to the present invention;

FIG. 22 is a front perspective view showing the mounting of the circuit board of FIG. 21 in a watthour meter socket adapter;

FIG. 23 is rear perspective view showing the printed circuit board and timer mounted in the socket adapter;

FIG. 24 is a perspective view of another embodiment of a safety shield according to the present invention usable with a current transformer rated watthour meter socket adapter;

FIG. 25 is a perspective view of another embodiment of a safety shield usable in a current transformer rated socket adapter;

FIG. 26 is a lateral cross-sectional view generally taken along lines 26—26 in FIG. 25;

FIG. 27 is a bottom perspective view of the safety shield shown in FIGS. 25 and 26,

FIG. 28 is a front perspective view of the socket adapter shown in FIG. 25, with the safety shield removed;

FIG. 29 is an enlarged, perspective view of a portion of the socket adapter shown in FIG. 28 depicting the mounting of potential jaw contacts;

FIG. 30 is a perspective view showing the various jaw contacts, blade terminals and jaw blade terminals mounted in the socket adapter depicted in FIG. 25;

FIG. 31 is an exploded perspective view of a jaw contact and blade terminal coupler according to the present invention;

FIG. 32 is a perspective view of the assembled jaw contact and blade terminal coupler of FIG. 31 of the present invention taken from a first side of the coupler;

FIG. 33 is a perspective view of the assembled jaw contact and blade terminal coupler of FIG. 31 taken from a second opposite side;

FIG. 34 is an exploded, perspective view of another aspect of a jaw blade coupler according to the present invention;

FIG. 35 is a perspective view of the coupler shown in FIG. 23, depicted in an assembled state;

FIG. 36 an end view of the coupler shown in FIG. 24; and

FIG. 37 is a partially exploded, perspective view of an alternated fuse carrying coupler.

DETAILED DESCRIPTION

In order to better describe and appreciate the advantages of the present invention, a description of the conventional construction of an electric watthour meter socket adapter or socket extender/adapter, both hereafter referred to as a socket adapter, will be provided with reference to FIGS. 1 and 2. A conventional socket adapter 10 includes contacts designed to receive blade terminals of a conventional electric watthour meter, not shown, in a releasable connection. The socket adapter 10 includes terminals, described hereafter, which plug into mating contacts in a watthour meter socket. The number of contacts and terminals in the socket adapter 10 will vary depending upon the type of electric service at a particular user site, FIG. 1 depicts, by way of example only, a single phase electric service.

As shown in FIGS. 1, 2, 3, and 4, the socket adapter 10 includes a base portion 12 and a shell portion 14 which are fixedly joined together by suitable means, such as fasteners. The base 12 has a central wall 16 of generally circular shape. A plurality of generally rectangular bosses 18 are formed on the central wall 16. Each of the bosses 18 has a slot 20 formed therein which extends completely through each boss 18 and the central wall 16 to receive a blade terminal therethrough, as described hereafter. A plurality of cylindrical bosses 22 are also formed on and extend outward from one surface of the central wall 16. Through bores are formed in each boss 22 for receiving a fastener to join the shell 14 to the base 12. A plurality of outwardly extending legs 24 are formed on a back surface of the central wall 16 and are provided in an appropriate number and spaced from one of the contacts or blade terminals which extends through the base 12.

An annular, raised, inner peripheral edge flange 30 is formed on the base 12 and extends outward from one surface of the central wall 16. An outer peripheral edge flange 32 is spaced radially outward from the inner flange 30. A plurality of circumferentially spaced ribs 34 extend radially between the inner and outer

peripheral edge flanges

30 and 32.

The inner peripheral edge flange 30 includes an annular seat for receiving a peripheral edge portion of the shell 14 when the shell 14 is engaged with the base 12. The outer peripheral edge flange 32 extends radially outward from the inner peripheral edge flange 30 and forms a mounting flange which mates with the mounting flange on the cover of the watthour meter socket, not shown. A conventional sealing ring, also not shown, is employed to surround and lockingly join the outer peripheral edge flange 32 to the mounting flange on the meter socket.

The shell 14 of the socket adapter 10 is formed with a generally annular sidewall 42. The sidewall 42 terminates in an enlarged diameter exterior end mounting flange 44. The mounting flange 44 is designed to mate with a corresponding mounting flange on a conventional watthour meter, not shown. A sealing ring, not shown, may be employed to encompass and lockingly connect the mounting flange 44 on the shell 14 and the mounting flange on a watthour meter.

The annular sidewall 42 of the shell 14 has an opposed annular edge 45 spaced from the exterior end mounting flange 44. A generally solid wall 46 is integrally connected to the sidewall 42 by a plurality of flanges 43 and is spaced between the exterior mounting flange 44 and the opposed edge 45. The wall 46 projects above the flanges 43 and acts as a dead front or safety shield covering all of the exposed portions of the jaw blades and an optional disconnect switch in a cavity between the base 12 and the shell 14.

The wall 46 has a plurality of raised bosses 47, each of which includes a slot 48 defining an opening for receiving a blade terminal 120 of an electrical device, such as a watthour meter, therethrough as shown in FIG. 11. Each raised boss 47 extends a short distance above the generally planar wall 46 and forms a recess or cavity 49 on the back surface of the wall 46 which receives and locates a jaw blade mounted on the base 12. Each slot 48 extends across the planar wall 46 and down a sidewall connecting the planar wall 46 to one flange 43 to permit easy angular insertion and removal of blade terminals through the slots 48.

As shown in FIG. 1, at least one and preferably two identical surge ground conductors 220 are diametrically mounted opposite each other on the mounting flange 44 of the shell 14. Each surge ground conductor 220 is removably mounted in one pair of slots in the mounting flange 44 and includes an arcuate wall portion 222 which conforms to the inner diameter of the annular sidewall 42 of the shell 14. The arcuate wall portion 222 has an upper edge 224 and a lower edge 226.

A pair of radially extending tabs 228 are formed on opposite side ends of the arcuate wall portion 222 generally adjacent the upper edge 224. Each tab 228 seats in the slots on the mounting flange 44 of the shell 14. Each tab 228 has an upper edge disposed slightly above the upper edge of the mounting flange 44. This places the upper edge of each surge ground conductor 220 at a position to electrically engage a ground terminal mounted on the rear surface of a conventional watthour meter.

Each surge ground conductor 220, as shown in FIG. 1, has a mounting foot or tab 230 connected to the lower edge 226 of the arcuate wall portion 222. The mounting foot 230 has a generally planar shape with apertures 232 positioned to receive fasteners to secure each surge ground conductor 220 to one of the bosses 22 in the base 12. Each aperture 232 is formed as a stamped threaded aperture so as to receive a threaded screw without need for a nut.

FIGS. 1-4 depict a

jaw blade

64, 66 and a spring clip 100 which are depicted as but one example of a jaw contact or jaw blade assembly which can be employed in the socket adapter 10. Further details concerning the construction and use of the

jaw blade

64, 66 and spring clip 100 can be had by referring to US Pat. No. 6,152,764, the entire contents of which are incorporated herein by reference.

As shown in FIG. 4, a pair of

load blade terminals

68 and 70 each comprise a generally planar member as is conventional in watthour meters and watthour meter socket adapters. One end of each

load blade terminal

68 and 70 is connected to two internal bus bars within a disconnect switch 60 shown only by example in FIGS. 1, 2 and 4. Outer ends 69 and 71 of the

load blade terminals

68 and 70 have a length sufficient to enable the outer ends 69 and 71 to project through the bottom or central wall 16 of the base 12 exteriorly of the housing of the socket adapter 10 for insertion into mating jaw contacts in a watthour meter, not shown.

It will be understood that the following described load jaw blade structure may also alternately be employed for the line jaw blade structure or for both the line and load jaw blade structures in the socket adapter 10.

By way of example, each of a pair of

load jaw blades

64 and 66, with only load jaw blade 64 being described in detail hereafter, includes a generally planar bus bar 74 which projects angularly and generally perpendicularly from the top surface of the housing of a switch 60. The planar bus bar 74 has an opposed first and second ends 76 and 78. Further, flange 80 projects angularly above and outward from the generally planar extent of the bus bar 74 to form a blade terminal guide as is conventional in watthour meter socket adapters.

The opposed load jaw blade 66 is identical to the load jaw blade 64, but is formed of a mirror image to form a pair of left and right

hand jaw blades

64 and 66. However, the spring clip 100 mounted on the load jaw blade 66 is identical to the spring clip 100 used with jaw blade 64.

A remotely controlled disconnect switch 60, shown in FIGS. 1, 2, and 4 as an option only, is located at the central wall 16 of the base 12. The disconnect switch 60 may be any commercially disconnect switch which may include an internally movable member and at least one pair of contacts which are electrically connected between one of the pair of line and load jaw blades within the socket adapter 10 and the corresponding one of the pair of line and load blade terminals projecting outwardly from the socket adapter 10 and to certain jaw contacts in a watthour meter socket, not shown. The switch 60 may be remotely actuated by means of signals provided on wires 62 which extend exteriorly of the housing of the socket adapter 10.

Referring now to FIGS. 5 and 6, there is depicted yet another embodiment of an electrical contact or jaw blade 526. The jaw blade 526 has an elongated shape and is particularly suited for use in a socket adapter extender 528 shown in FIG. 6. The socket adapter extender 528 is similar to the socket adapter 402 described hereafter with several modifications. The housing of the socket adapter extender 528 includes a generally planar base or bottom wall 530 and lower sidewall 532. The sidewall 532 terminates at a radially outward extending mounting flange 534. The mounting flange 534 has an inward extending, annular shelf 536 disposed interiorly within the socket adapter extender 528 and an outwardly extending flange terminating in a depending lip 538 spaced from the lower sidewall 532. The lip 538 is positioned for receiving a sealing ring to mount the socket adapter extender 528 on a ring-style socket adapter cover, not shown. An upper sidewall 539 extends from the mounting flange 534 and terminates in a mounting flange.

The jaw blade 526 has a unitary, one piece construction formed of a blade terminal end 542 which is offset by an intermediate offset 544 from an elongated jaw contact end 546. A blade terminal edge guide 548 is formed at one end of the jaw contact end 546.

A pair of

side flanges

550 and 552 project perpendicularly from opposite side edges of the jaw contact end 546 and extend from an upper end adjacent the blade terminal guide 548 and to an opposite end 554 approximate the intermediate offset 544. The second end 554 of each

side flange

550 and 552 seats on the base 530 of the socket adapter extender 528 to prevent sideways movement of the jaw blade 526 relative to the base 530.

A spring clip 558 is fixedly connected to the jaw contact end 546 by two fasteners, such as rivets, not shown, extendible through apertures 559. The upper end of the spring clip 558 angles outwardly to form a mating blade terminal guide 548 on the jaw contact end 546. The end 560 of the spring clip 558 is spaced from the adjacent jaw contact end 546 to define a slot for receiving a watthour meter blade terminal in a conventional manner.

Referring now to FIGS. 7-9, there is depicted a jaw contact safety shield 580 which is mountable in the socket adapter extender 528. The safety shield 580 is formed of a one piece electrically insulating material, such as a suitable plastic, and is formed of an enclosure which, when the safety shield 580 is mounted in the socket adapter extender 528, completely surrounds all of the line and load jaw blades within the socket adapter extender 528 except for small slots allowing the insertion of a watthour blade terminal into engagement with each line and load jaw blade.

The safety shield 580 includes a top or outer wall 582 and a plurality of sidewalls all denoted by reference number 584. A plurality of raised bosses 586 are formed in the top wall 582. The bosses 586 are positioned at the normal jaw contact positions of a watthour meter socket adapter.

Each boss 586 has an aperture or slot 588 formed therein. Each slot 588 has a top wall portion 590 extending parallel to the plane of the top wall 582 and a contiguous sidewall portion 592 forming a continuous L-shaped slot along the top wall 582 and the sidewall 584 of the safety shield 580. The unique provision of the sidewall slot portion 592 simplifies the insertion and removal of a watthour meter into and out of the jaw contacts of the socket adapter extender 528 through the safety shield 580.

A peripheral flange 594 extends outward from a lower edge of the sidewall 584 of the safety shield 580. The peripheral flange 594 has a polygonal or square shape, by example only. Other shapes, such as octagonal, round, etc., may also be employed.

A plurality of legs 596 project from the peripheral flange 594, generally at each corner of the peripheral flange 594. Each leg 596 has a generally planar configuration with a notched inner surface 598. A slot 600 is formed on the outer side of each leg 596 extending from the peripheral flange 594 to an aperture 602 in each leg 596.

Latch means is provided for releasably latching each leg 596 and the entire safety shield 580 in the socket adapter extender 528. The latch means includes a plurality of apertures 604 formed in the lower sidewall 632 of the extender 528 adjacent to the mounting flange 534 as shown in FIG. 8. A latch projection 606 is unitarily formed with the sidewall 532 and projects outwardly therefrom. The latch projection 606 has a flat edge surface 608 for releasable engagement with the aperture 602 in each leg 596 as shown in FIG. 9. As the legs 596 of the safety shield 580 are urged toward each latch projection 606, the outer end of each leg 596, which has an angled end surface 610, rides along the latch projection 606 until the aperture 602 slides over the edge 608 of the latch projection 606 releasably latching the leg 596 to the housing of the extender socket adapter 528. Since the aperture 604 in the sidewall 532 opens outwardly underneath the mounting flange 534, the legs 596 of the safety shield 580 may be released from the latch projection 606 by forcing a tool, such as a screwdriver, underneath the lower end of each leg 596 disengaging the leg 596 from the latch projection 606.

A modified safety shield 620, which is substantially similar to the safety shield 580 shown in FIG. 7 is depicted in FIGS. 10 and 11. Accordingly, like reference numbers are used to identify like components in both of the safety shields 580 and 620.

In this embodiment, the plurality of legs 622 are also located at the outer corners of the safety shield 620. Each leg 622 terminates in an outwardly extending latch projection 624 which is positioned to engage an inner lip 626 formed in the sidewall 539 adjacent the mounting flange 532 as shown in FIG. 11 to releasably latch the safety shield 620 to the housing of the socket adapter extender 528. The latch projection 624 is accessible from the bottom of the mounting 532 and can be urged radially inward from the mounting flange 532 to disengage the latch projection 624 from the lip 626 and enable the safety shield 620 to be removed from the extender 528.

Referring now to FIGS. 12 and 13, there is depicted another embodiment of a jaw contact safety shield 630 which is particularly suited for use with a low profile socket adapter, not shown, having a short height sidewall. Again, since the safety shield 630 is similar to the safety shields 580 and 620 described above, like components are depicted by the same reference number. In this embodiment, a pair of spaced end flanges 632 are formed on opposite portions of the sidewalls 584 and project outwardly from the adjacent sidewall 584. Each end flange 632 has a pair of downwardly depending legs 634 extending therefrom, each leg 634 terminating in an outwardly extending latch projection 636. The latch projection 636 on each leg 634 in releasably insertable through an aperture in the base and the adjacent ring of a socket adapter in the same manner as the latch projection 624 engages an aperture in the sidewall 539, as shown in FIG. 11.

As shown in detail in FIG. 13, each latch projection 636 snaps into engagement with an underlying surface 640 on the sidewall of the socket adapter housing to releasably mount the safety shield 630 to the housing. Each latch projection 636 may be released from engagement with the back surface of the base 637 of the socket adapter by means of a sharp tool inserted from behind the base 637.

FIGS. 12 and 14 depict a unique feature of the safety shields 630, 580 and 620. As shown therein, one leg 640 of the boss 586 adjacent to the slot 588 positioned at the eighth jaw contact position is cantilevered from an outer edge adjacent the sidewall 584. This provides the cantilevered flange 640 with a freely movable end 642 which enables the flange 640 to bend inward about the outer edge in a watthour application where a single phase watthour meter has a potential clip at this position. The potential clip engages the flange 640 and bends it inward about the outer end enabling the watthour meter to properly seat in the socket adapter.

Referring now to FIGS. 15-18, there is depicted a modification to the above-described safety shield in which a safety shield 110 is mounted in the socket adapter extender 528 in a unique manner. Further, it will be understood that the safety shield 110 may also be employed in other types of socket adapter housing constructions.

The safety shield 110 is formed of a one piece, electrically insulating material and has a construction which, when mounted in the socket adapter extender 528, completely surrounds and substantially encloses all of the line and load jaw blades within the socket adapter extender 528 except for small slots allowing the insertion of watthour blade terminals into engagement with each line and load jaw blades or contacts.

The safety shield 110 includes a top or outer wall 112 and a peripheral sidewall 114 depending therefrom. The top wall 112 and the sidewall 114 are depicted by example only as having a generally square configuration. A pair of opposed outwardly extending

side edge flanges

116 and 118 project from the lower edges of two opposed sidewalls 114. A pair of laterally extending

flanges

120 and 122 project perpendicularly outward from opposed sidewalls 114. An outer end of each

lateral flange

120 and 122 communicates with perpendicular, downward depending

sides

124 and 126, respectively. The

sides

124 and 126 are oriented, when the safety shield 110 is mounted with the socket adapter extender 528, immediately adjacent to the inner wall of the

surge ground conductors

128 and 130, respectively.

A plurality of raised bosses 132 are formed in the top wall 112 and are located at the normal jaw contact positions of a watthour meter socket adapter. Each boss 132 has an aperture or slot 134 extending therethrough. As described above, the slots 134 extend over the top wall 112 and along the sidewall 114 to permit easy, angled insertion and/or removal of a watthour meter blade terminal into and out of contact with a jaw contact position behind each slot 132.

A polygonal or rectangular shaped aperture 136 is formed in each

lateral flange

120 and 122 for enabling mounting or access to a current transformer shorting switch 121. The aperture 136 can also serve as a mounting window for any connector, such as a multi-pin connector, also not shown.

As shown in FIGS. 15, 17 and 18, at least one and preferably two circumferentially spaced receivers or

bosses

138 and 140 are formed on the outer edge of each

lateral flange

120 and 122 and surround a flat 142 shown in FIG. 18. The flat 142 is positioned approximately in line with one

lateral flange

120 and 122. Each

boss

138 and 140 and the associated flat 142 form a radially outward opening cavity 144.

The

surge ground conductors

128 and 130 are identically constructed. The two

ground surge conductors

128 and 130 are diametrically mounted opposite each other on the mounting flange 44 of the socket adapter extender 528 in a pair of slots 146 formed in the mounting flange 44.

As clearly shown in FIG. 16, each

surge ground conductor

128 and 130 includes an arcuate wall 148 which conforms to the inner diameter of the annular sidewall 539 of the socket adapter extender 528. A pair of radially extending tabs 150 are formed on an upper edge 152 of each

surge ground conductor

128 and 130 and seat within one of the slots 146 in the mounting flange 44 to support each

surge ground conductor

128 and 130 from the mounting flange 44 of the socket adaptor extender 528. The upper edge 152 of each

surge ground conductor

128 and 130 overlays a portion of the mounting flange 44 and is in position to electrically engage a ground terminal mounted on the rear surface of a conventional watthour meter.

As shown in FIG. 16, each

surge ground conductor

128 and 130, has a lower mounting foot 154 which is formed as an extension of the arcuate sidewall 148. The mounting foot 154 has a distal end 156. An aperture 158 is formed within the mounting foot 154 and surrounds a tab 160 which integrally extends from the end 156. In use, the mounting foot 154 is bent generally perpendicularly outward from the arcuate sidewall 148, in a direction opposed to the radially inward extending direction of the tab 160. This bending movement of the mounting foot 156 enables the mounting foot 154 to slide through an aperture formed in the sidewall 539 of the socket adapter extender 538 to secure the

surge ground conductor

128 or 130 in position on the sidewall 139 of the socket adapter extender 528.

According to a unique feature of the present invention, each

surge ground conductor

128 and 130 is formed with at least one and preferably two arcuately spaced

fingers

162 and 164. Each pair of the

spring fingers

162 and 164 has an angularly bent portion projecting away from the surface of the arcuate sidewall 148. Each of the

spring fingers

162 and 164 is spaced from opposite sides of the arcuate sidewall 148 as shown in FIG. 16. The distal end of each of the

spring fingers

162 and 164 is positioned to engage the cavity 144 formed by the boss 140 and the flat 142 in the

lateral flanges

120 and 122 of the safety shield 110 to securely retain the safety shield 110 in position within the interior of the socket adapter 110. In this mounting position shown in FIG. 17, the bottom edge of the arcuate sidewalls 148 directly seats on the interior ring of the socket adapter extender 528. This mounting arrangement eliminates the use of any separate mechanical fasteners to fixedly mount the safety shield 110 within the interior of the socket adapter extender 528. At the same time, the safety shield 110 can be easily removed by merely urging the distal ends of each of the

spring fingers

162 and 164 radially outward until the distal ends of each

spring finger

152 and 164 disengage from the flats 132 on the

lateral flanges

120 and 122 in the safety shield 110.

Referring now to FIG. 19, there is depicted a socket adapter 400 which has means for mounting or supporting auxiliary components, such as generally planar circuit boards 653, adjacent to or preferably on the base 402. The mounting means comprises at least one pair and, preferably, a plurality of pairs of posts 650 which are arranged in diametrically opposed pairs. Each post 650 is formed at the juncture of the base 402 and the ring 406 of the socket adapter 400 and extends upward therefrom. A U-shaped channel 652 is formed in each post 650. The U-shaped channel 652 in one post is linearly aligned with a U-shaped channel of a post 650 in one adjacent pair of posts 650 as shown in FIG. 19. This arrangement forms a pair of channels 652 adjacent to the inner surface of the sidewall 412 of the socket adapter 400.

Although the peripheral flange 594 of the shield 620 may be cut out or shortened to allow the circuit boards 653 mounted within the pairs of posts 650 to extend upward along side of the sidewall 592 of the shield 620, in a preferred embodiment, as shown in FIGS. 31 and 32, a U-shaped slot 654, one wall of which is shown in FIGS. 31 and 32, is integrally formed adjacent to opposite side edges of each leg 622 of the shield 620 and engage the upper end of a circuit board 653 disposed adjacent to each slot 654. In this manner, the circuit board 653 is mounted in the channels 650 and slots 654 and is seated against the peripheral flange 594 of the shield 620.

Also shown in FIG. 19 is further modification to the socket adapter 400, or more preferably, the socket adapter 528, in which at least four and preferably more standoffs 656 are mounted on the base 402 of the socket adapter 400 for securing a circuit board, not shown, in a horizontal orientation between the line and

load jaw blades

416 and 418. Screws are insertable through apertures into the circuit board into the stand offs 656.

FIG. 20A shows a further modification to the socket adapter 400 in which the socket adapter 400 is devised for carrying one or more circuit boards 653 at various positions inside of the sidewall 412. Although FIG. 20A depicts the pairs of posts 650 generally arranged in two diametrically opposed pairs, it will be understood that the embodiment shown in FIG. 20A need not necessarily include such posts 650.

Auxiliary support members

658, 660 and 662 are provided at various locations about the periphery of the sidewall 412 at the juncture of the sidewall 412 and the base 402. In addition to a mounting function, the posts and support members also add strength to the sidewall-base joint of the one piece socket adapter housing.

The auxiliary support members may take a variety of forms as shown by the

different support members

658, 660 and 662. The

support members

658, 660 and 662 all include at least one or more U-shaped slots 664. The

support members

658, 660 and 662 are arranged in opposed pairs, as shown in FIG. 20A, by example only, such that one slot in one support member linearly aligns with one slot in an opposed support member. The pairs of aligned slots are thus capable of supporting opposite edges of a circuit board 653 oriented perpendicularly with respect to the base 402 of the socket adapter 400. This enables many circuit boards 653 to be housed within the socket adapter 400 between the jaw contact ends of the line and

load jaw blades

416 and 418. The

support members

658, 660 and 662 may also be provided outside of the shield 620 to support a circuit board between the sidewall 412 and the sidewall 594 or the shield 620.

Another aspect of the present is shown in FIG. 20B which depicts a printed circuit board 653 mounted between two aligned support members 650 and extending laterally across all of the line blade terminal receiving slots 404 in the base of the socket adapter 400. An electrically conductive spring tab 655 is soldered or otherwise fixedly mounted on the printed circuit board 653 in electrical communication with conductive members of the circuit board 653. The tab 655 extends outward from the printed circuit board 653 to a position which intersects with a line blade terminal 657 inserted through the slot 404 in the base of the socket adapter 400. The tab 655 enables line power from the line blade terminal 657 to be applied to the printed circuit board 653 to power electrical components mounted on the printed circuit board 653.

In addition to mounting circuit boards in a vertical, orientation between aligned pairs of slots along the periphery of the interior sidewall and base of the socket adapter extender 528, one or more circuit boards may also be mounted between any two blade terminal apertures. A circuit board 168, shown in FIGS. 21A, 22 and 23, is mounted through the

slots

170 and 172 in the base 530 which normally receive the fifth and sixth terminals of a watthour meter socket adapter, if present in a particular meter.

It will be understood, however, that the circuit board 168 could also be mounted between any pair of line and load contact receiving slots as described hereafter.

As clearly shown in FIG. 21A, the circuit board 168 has a conventional planar circuit board shape with a at least one and, preferably, a pair of depending

terminal portions

174 and 176 which are sized to be slidably inserted through the

slots

170 and 172 in the base 530. Apertures 178 may be formed in each terminal end for receiving a cotter pin or other fastener to securely retain the printed circuit board 168 in position. Electrically conductive pads or terminals 179 such as a copper foil pad bonded to the circuit board, are carried on the legs 174 for connection to an electrical circuit or component external to the socket adapter 528 by a jaw connection, connector, solder or clamp connection.

The printed circuit board 168 may be used as a mounting surface for any electrical, electromechanical or electronic component or circuit which is used in a watthour meter socket adapter.

In addition to the use of fasteners or cotter pins extending through the aperture 178 in the terminal ends 174 and 176, the circuit board 168 may also be secured in position by means of an engagement with the bent tab 160 on each

surge ground conductor

128 and 130 shown in FIG. 16. The tabs 160 are designed to slid into arcuate shaped notches 121 formed in opposed side edges of the printed circuit board 168 as shown in FIG. 21A.

In one example of an application or use of the printed circuit board 168, as shown in FIGS. 22 and 23, a timer 182 is mounted on the circuit board 168. The timer 182 includes a face plate or dial 184, shown in FIG. 23 which is visible thorough an aperture 186 formed in the base 530 of the socket adapter extender 528. A time display 188 as well as individual pushbuttons or switches 190 and 192 are also mounted on the dial 184 for controlling operation of the timer 182, such as setting the current time, resetting the time. Event times may also be programmed via the switches 190. An output signal from the timer 182 at one event time may energize one or more relays mounted on the circuit board 168 to control components within the socket adapter extender, such as a power disconnect switch, service limiter, etc., to break the circuit between the line and load contacts to shed loads, such as a hot water heater, at a preprogrammed time.

Referring now to FIG. 21B, there is depicted a modified circuit board 710. The circuit board 710 can be mounted between any aligned pair of apertures in the base of a socket adapter, such as between the fifth and sixth terminal positions, or between any pair of line and load terminal positions. In this embodiment, the circuit board 710 is provided with a two pairs of apertures, not shown, located near the upper edge of the circuit board 710. A conventional socket adapter jaw contact 712 is mounted to the circuit board 710 by means of fasteners extendable through apertures in the jaw contact 712 and the apertures in the circuit board 710. Thus, the jaw contacts 712 can comprise a three finger jaw contact as shown in FIG. 30, and described hereafter. By way of example only, the jaw contact 712 comprises a pair of contact clips 714 which are mounted on opposite sides of the circuit board 710 in an aligned pair. Each of the clips 714 includes apertures alignable with the apertures in the circuit board 710 for receiving mechanical fasteners, such as rivets, therethrough to affix the contact clips 714 to the circuit board 710. The contact clips 714, on at least one side of the circuit board 710, are electrically connected to conductive traces 716 conventionally formed in the circuit board 710. A spring clip 718 is mounted on each contact clip 714 and has an end portion which biases the contacting portions of each contact clip 714 toward the opposed contact clip 714 to provide a secure electrically connection between the contact clip 714 and an inserted electrical terminal.

The contact clip 714 as well as the spring clip 716 may be formed as a one piece member having a single end portion. Alternately, as shown in FIG. 21B, each contact clip 714 and each spring clip 716 may be soldered to form two end portions. Further, the end portions of each contact clip 714 may be provided at different lengths to provide a staggered electrical terminal insertion force.

As also shown in FIG. 21B, the conductive pads 179 mounted on the

terminal end portions

174 and 176 of the circuit board 710 are also electrically connected to conductive traces 720 carried on the circuit board 710. Any electrical circuit or electrical component may also be mounted on the circuit board 710 and electrically connected to the

conductive traces

716 and 720 in a conventional manner.

FIG. 21C depicts a further modification to the circuit board 710. In this aspect of the invention, each jaw contact clip 724 is mounted directly on the circuit board 710 such that the contact fingers of each contact clip 724 are spaced from a conductive pad 726, such a copper foil pad, bonded or otherwise mounted on the circuit board 710. In this aspect of the invention, each jaw contact clip 724 and opposed conductive pad 726 form a single jaw contact for receiving a blade terminal therebetween in electrical connection.

Further, the terminal end portions of the circuit board 710, in this embodiment, may be formed solely by flat, electrically conductive plates 728, such as copper-tin plates which are fixedly mounted to the circuit board 710 by means of fasteners, such as rivets mounted through aligned apertures in each plate 728 and the lower portion of the circuit board 710. It is also feasible, in the present invention, to directly overlay the conductive plates 728 on the

terminal portions

174 and 176 extending from the main portion of the printed circuit board 710.

One or more relays may be mounted on the printed circuit board 710, each relay including at least one switchable contact which is movable between a normally open and a normally closed position. The contact terminals can be electrically connected by separate wires or conductors or by means of conductive traces on the circuit board 710 between one jaw contact 712 and one plate terminal portion 179 in the embodiment shown in FIG. 21B or between one

jaw contact

724, 726 and one conductive terminal plate 728 in the embodiment shown in FIG. 21C. The relay(s) can serve as a power disconnect or service limiter such that in normal operation, the relay contacts are closed allowing electrical current to flow between one jaw contact and one associated conductive plate or blade portion. However, when the relay(s) are activated, the contacts switch positions to an open position thereby opening or breaking the circuit between each jaw contact and blade terminal pair to disconnect electrical power to the use site.

Referring now to FIG. 24, there is depicted a safety shield 400 which is specifically designed for use in a current transformer rated watthour meter socket adapter 402. In general, the safety shield 400 is similar to the safety shield 580 described above and shown in FIG. 7 in that it includes a top wall 403, a plurality of depending sidewalls 404, and a peripheral flange 406 projecting generally perpendicularly outward from each sidewall 404. A plurality of raised bosses 408 extend upward a slight distance above the surface of the top wall 403 and carry individual slots 410 opening to the interior of the shield 400 and providing access to jaw contacts mounted on the base of the socket adapter 402. The top wall 403 is also formed with a plurality of laterally spaced dividers or walls 412 which form laterally spaced apertures 414 between adjacent dividers 412. Further, in a centrally located, raised portion 416, a plurality of laterally spaced slots 418 are formed to provide access to current transformed rated jaw contacts mounted within the socket adapter 402, as described hereafter.

The safety shield 400 may be securely or fixedly mounted to the socket adapter 402 by any of the mounting or latch means described above for the safety shields 580 and 620.

FIGS. 25 and 26 depict a modified safety shield 420 which is similar to the safety shield 400 in that it includes raised bosses 408 extending from a top wall 403, slots 410 formed in each boss 408, spaced dividers 412 forming laterally spaced apertures 414, and a raised portion 416 carrying laterally spaced slots 418. However, in this embodiment, the top wall 403 has a greater lateral extent so as to closely conform to the inner sidewall of the socket adapter 402. A polygonal shaped aperture 422 is formed along one lateral side edge of the top wall 403 for receiving a current transformer shorting switch, or electrical pin connector, not shown.

Opposed pairs of raised bosses 424 formed along lateral opposed side edges of the top wall 403 and form recesses designed to receive

spring fingers

162 and 164 on the

surge ground conductors

128 and 130 in the same manner as described above and shown in FIGS. 15-18. In this manner, the

spring fingers

162 and 164 on the

surge ground conductors

128 and 130 fixedly, yet releasably mount the safety shield 420 within the interior of the socket adapter 402.

The safety shield 420 is formed with a pair of spaced

arcuate sidewalls

428 and 430 which are diametrically opposed on opposite sides of the safety shield 420. The

arcuate sidewalls

428 and 430 are disposed adjacent to the arcuate wall portions 148 of the

surge ground conductors

128 and 130.

As shown in FIG. 27 which depicts a rear or bottom view of the safety shield 420, a rectangular frame 432 formed of four interconnected sidewalls projects from the rear surface of the top wall 403 of the safety shield 420. The dividers 412 extend from the top to the bottom of the frame 432 and between opposed elongated sidewalls of the frame 432. The frame 432 and spaced dividers 412 form a plurality of pairs of cavities, including the cavities 414 opening through the top wall 403 of the safety shield 420 and a plurality of interior cavities 434 opening to the slots 428 in the top wall 403 and defining a jaw contact mounting area.

The frame 432 also includes a first laterally extending wall 436, a spaced second laterally extending wall 438 and a plurality of intermediate short walls 440 which extend between each of the dividers 412. An enlargement 442 having a tapered or angled edge 444 on one side thereof facing the cavity in the frame 432 opening to the slots 418. The angled or tapered surface 444 acts as a guide for urging the potential jaw contacts into the proper location within the cavity in the frame 432 into alignment with the slot 418 so as to be positioned to receive a blade terminal of a watthour meter inserted through the slot 418.

FIGS. 28 and 29 depict interior views of the socket adapter 402, with the shield 400 removed. As shown in FIG. 28, the socket adapter 402 includes the generally planar base 450 and an annular sidewall 452 projecting therefrom. A plurality of line and load watthour meter blade terminal receiving slots 454 are formed in the base 450 at the normal watthour meter blade terminal positions. In order to support auxiliary electrical contacts on the base 450, a plurality of posts 456 are integrally formed with the base 450 and project generally perpendicularly therefrom. The posts 456 are disposed between the line and load jaw blade receiving slots 454. The posts 456 have a generally square cross section extending from a common lower portion 458 and are laterally spaced across the base 450.

An aperture 460 is formed in the top end of each post 456 for receiving a fastener or screw as described hereafter. Also, a notch 462 is formed in the outer end of each post 456 and has a configuration for receiving a planar flange on an electrical contact as described hereafter.

A barrier 464 is also formed on the base 450 and is spaced from the posts 456. The barrier 464 also extends laterally across the base 450 and has a plurality of laterally spaced recesses 466 which divide the barrier into a plurality of walls 468. Each wall 468 has a top edge 470 and a stepped recess formed on one side facing the posts 456. The recess is formed with a first shallow notch 472 and a second, adjacent, deeper notch 474.

A pad 476 is formed on the base 450 of the socket adapter 402 and extends between one post 456 and one wall 468. A generally rectangular slot 478 is formed between two adjacent pads 476. The slots 478 open through the base 450 of the socket adapter 402 and are sized to receive one end of a conventional blade terminal, as described hereafter.

Although each of the safety shields 110, 400 420, 580, 620 and 630 have been described above as being releasably mountable in a watthour meter socket adapter housing by a snap-in connection, it will be understood that each safety shield, instead of the snap-in connection, or in combination with the snap-in connection, may be more fixedly mounted in the housing of a socket adapter by applying adhesive between adjoining portions of each safety shield and adjacent wall surfaces of the socket adapter housing, or the wall portion 148 of the surge ground conductor 128 shown in FIG. 17. While referring briefly to FIG. 17, adhesive can also be applied to the bottom edge of the safety shield 110 and the upper surface of the ring or collar formed on the inner surface of the sidewall 539 of the socket adapter 528.

Before describing mounting of the electrical contacts on the posts 456 and walls 468, a brief description of the construction of several configurations of electrical contacts will be provided.

One embodiment of an electrical contact 480 is shown in FIGS. 29 and 30. The electrical contacts 480 are identical to the three finger jaw contacts disclosed in U.S. Pat. No. 5,853,300, assigned to the Assignee of the present invention, the entire contents of which pertaining to the three finger contact construction are incorporated herein by reference.

In general, each contact 480 has a three finger jaw-type contact design formed of first and second

outer legs

482 and 484 which extend linearly from a generally planar base 486. Each of the

legs

482 and 484 terminates in a angularly bent outer end portion, both of which extend in the same direction to one side of the base 486. An intermediate leg 488 is disposed between the

outer legs

482 and 484 and has a generally curved shape extending from the base 486 to an opposite side of the base 486 from the outer ends of the

outer legs

482 and 484. The outer ends of the intermediate leg 488 also curves or bends outward from one side of the base 486 to form, in conjunction with the

legs

482 and 484, a jaw contact which receives a blade terminal extending outward from the base of a watthour meter, not shown.

A wire crimp collar 490 formed of two angularly disposed, bendable flanges, extends from one end of the base 486. The two flanges of wire crimp collar 490 are bendable into registry with one end of an external conductor, not shown, to electrically connect one end of the external conductor to the contact 480. Alternately, solder may be used to connect the external conductor to the flanges of the wire crimp collar 490.

A support flange 492 is formed contiguous with the base 486 and extends generally perpendicularly from an opposite end of the base 486. A threaded aperture 494 is formed in the support flange 492 and is alignable with the aperture 460 on the top edge of one post 456. A screw fastener, not shown, threadingly engages the aperture 494 on the support flange 492 and the aperture 460 in the post 456 to fixedly mount the jaw contact 480 on the base 450 of the socket adapter 402. An external conductor, not shown, may also be connected to the support flange 492 by connecting the external conductor to the screw fastener extending through the aperture 494 in the support flange 492. A washer may be interposed between the head of the screw fastener in the support flange 492 for secure electrical engagement of the external conductor with the support flange 492.

Finally, a mounting tab 496 extends perpendicularly from an outer end of the support flange 492. The mounting tab 496 provides a separate connection to another external electrical conductor, not shown, such as a conventional fast-on or quick connector which is fixedly attached to one end of an electrical conductor and slidable engaged over a complimentary formed mounting tab 496 to connect the external conductor to the contact 480.

Referring again to FIGS. 29 and 30, one jaw contact 480 is mounted on one aligned pair of a post 456 and a wall 468. One end of the base 486 projecting downward from the wire crimp collar 490 is seated in the deeper notch 474 in the wall 468. Since the notch 474 extends only a short distance along the wall 468 from the top edge 470, one end of the contact 480 is located such that the wire crimp collar 490 seats on the top edge 470 of the wall 468 and the support flange 492 rests on the top edge of the post 456, with the end portion of the base 486 seated within the notch 462 in the post 456.

A planar blade terminal 500 is associated with the contact 480. The blade terminal 500 has a generally planar extent with intermediate shoulders 502 designed to seat on the base 450 of the socket adapter 402, with the lower portion of the blade terminal 500 extending through one slot 478 in the base 450. The blade terminal 500 is secured in position within the socket adapter 402 by means of a cotter pin, not shown.

Referring briefly to FIGS. 24-27, when the contact 480 is in the mounting position shown in FIG. 29, the

legs

482, 484 and 486 defining the contact itself are aligned with one slot 418 in the shield 400 thereby allowing a blade terminal from the watthour meter to be inserted through the slot 418 in the safety shield 400 into contact with the

jaw contact legs

482, 484, and 486. At the same time, the support flange 492 as well as the fast-on tab 496 are accessible through the aperture 418 in the shield 400 to allow electrical connections with external electrical conductors.

Referring again to FIGS. 29 and 30, there is depicted another embodiment of an electrical contact or blade terminal 504 which can be mounted in the socket adapter 402. The jaw blade terminal 504 has a one-piece construction which combines the three finger jaw contact structure of the jaw contact 480 with an integral blade terminal similar to the separate blade terminal 500. The three

legs

482, 484, and 486 are shown in FIG. 30 at one end of the elongated, planar bar 506 which is part of the jaw blade terminal 504. Shoulders 502 are formed adjacent the blade terminal end of the jaw blade terminal 502 and seat on raised portions 508 extending between adjacent tabs 476 on the base 450 of the socket adapter 402. One side edge of the upper portion of the planar bar 506 seat in the shallow notch 472 on the wall 468. The opposite side edge of the upper portion of the planar bar 506 rests against the sidewall of a post 456 to position the jaw contact 504 between one post 456 and one wall 468 and to enable the jaw contact end of the jaw blade terminal 504 to be positioned below and accessible through one slot 418 in the shield 400 as shown in FIG. 26.

Finally, a coupler 750 is depicted in FIGS. 31-33 for joining an electrical contact 752 with a planar blade terminal 752 into a unitary construction which may be mounted as a unitary jaw blade terminal in the socket adapter 402 in the same manner as the jaw blade terminal 504. The coupler 750 is formed of an electrically insulating material, such as a plastic, to electrically isolate the jaw contact 752 from the blade terminal 754.

The jaw contact 752 is a modified version of jaw contact 480 and is essentially the same as the jaw contact 480 except that jaw contact 752 does not include the support flange 492 and fast-on tab 496. For convenience, the three

legs

482, 484 and 488 forming the jaw portion of the jaw contact 752 are given the same reference numbers as the corresponding legs in the jaw contact 480. Likewise, a wire crimp collar 490 projects from one end of a base 496.

The coupler 750 is exemplary formed as a one piece, unitary body having a first elongated sidewall 756, and an opposed shorter sidewall 758 which are interconnected by upper and

lower center walls

760 and 762, respectively, which are spaced apart along the length of the

sidewalls

758 and 760.

The upper center wall 760 has a generally U-shape formed of a center portion 764 which is offset or spaced from a pair of

base flanges

766 and 768 projecting from the

sidewalls

756 and 758, respectively, as well as a pair of

side flanges

770 and 772 which also project from the

sidewalls

756 and 758, respectively, to form a slot which receives the base 486 of the jaw contact 752. The

base flanges

766 and 768, the

side flanges

770 and 772 as well as the center portion 764 of the upper center wall 760 interact along with a slot 778 formed between a pair of spaced projections in the upper end of the sidewall 756 to securely support the jaw contact 752 in the coupler 750. The slot 778 engages an outwardly projecting side edge 780 on the leg 482 of the jaw contact 752.

The jaw contact 752 is also retained in place in the coupler 750 by means of a projection 782 which is formed on one end of a cantilevered, resilient arm 784 which projects from one end of the center wall 764 into an opening formed in the center portion 764 as shown in FIG. 31. The projection 782 engages an aperture 785 in the base 486 of the jaw contact 752.

The lower center wall 762 is spaced from inwardly projecting

side flanges

788 and 790 formed on one end of the

sidewalls

756 and 758, respectively, to form openings which slidably receive the planar blade terminal 754 therein. A pair of raised dimples 792 spaced from one end of the blade terminal 754 snap over the center wall 762 of the coupler 750 to slidably trap the blade terminal 754 between an upper edge of the lower center wall 762 and inwardly facing projections on the

sidewalls

756 and 758. A cotter pin or other fastener may be inserted through an aperture 794 in the blade terminal 754 to more securely retain the blade terminal 754 in the coupler 750.

Referring briefly to FIGS. 27 and 31-33, a plurality of U-shaped channels 796 project from the back surface of the top wall 403 of the safety shield 420. The U-shaped channels 796 are formed adjacent to one lateral leg of the frame 432 at one end of certain slots 410 in the safety shield 420. The U-shaped channels slidably receive the upper end 798 of the sidewall 756 of the coupler 750 to accurately mount the coupler 750 with respect to one slot 410 in the safety shield 420.

Referring now to FIGS. 23-25, 34-36, there is depicted another aspect of a coupler 810 constructed in accordance with the present invention. The coupler 810 is usable with a jaw contact 812 formed of a spring clip 814 which is fixedly joined, such as by rivets 816, to a contact member 818. The end 820 of the spring clip 814 is angled outward to form an open jaw with a corresponding oppositely angled end 822 of the contact member 818.

The contact member 818 has a planar wall 840 which faces and is electrically coupled to the end portion of the spring clip 814 by the fasteners 816.

Apertures, not shown, may be formed in the wall 840 for receiving the rivets or other fasteners 816. An aperture 824 is formed in one end of the wall 840 for receiving a fastener, the purpose of which is described hereafter.

By way of example only, the contact member 818 has a one piece, U-shaped, channel configuration wherein

opposed sidewalls

826 and 828 project angularly, such as perpendicularly, from opposite side edges of the wall 840. As shown in FIGS. 23 and 24, the spring clip 814 is disposed between the

sidewalls

826 and 828.

A blade terminal 830 includes an elongated, planar blade 832 having an aperture 834 for receiving a fastener, such as a cotter pin, not shown, for fixing the blade terminal 830 in a watthour meter socket adapter, with the end portion of the blade 832 projecting externally of a base wall of a socket adapter.

The opposite end of the blade 832 is formed as a U-shaped channel 836. The channel 836 includes a pair of

opposed sidewalls

838 and 840 which extend generally perpendicularly from opposite side edges of a central portion 842 of the blade 832.

The coupler 810 is devised for mechanically connecting, but electrically isolating the jaw contact 812 from the blade terminal 830; while fixing the jaw contact 812 and the blade terminal 830 in a unitary assembly. The coupler 810 has a generally planar body 843 with

apertures

844 and 846 formed therethrough generally adjacent opposite longitudinal ends of the coupler 810. The coupler 810 is formed of an electrically insulated material, such as a suitable plastic, which has sufficient strength to mechanically fix the jaw contact 812 to the blade terminal 830.

In use, as shown in FIGS. 23-25, a washer 850, which may be a lock or Belleville washer, and a nut 852 are interposed between each of the

apertures

844 and 846 in the coupler 810 and the aperture 824 in the jaw contact 812 and the aperture 835 in the jaw blade 830, respectively. A bolt 854 can be inserted through the aligned apertures in the jaw contact 812, the blade terminal 830, the washers 850, the nuts 852 and the

apertures

844 and 846 in the coupler 810 and tightly secured in place by means of another nut 856 on the outside of the body 843. This fixedly and mechanically couples the jaw contact 812 to the blade terminal 830. However, due to the electrically insulating nature of the coupler 810, the jaw contact 812 is electrically isolated from the blade terminal 830. This enables

external conductors

860 and 862 to be electrically connected to the jaw contact 812 and the blade terminal 830, respectively. The

conductors

860 and 862 are fixed to the coupler 810 via the nuts 852 at one end and extend to external connections outside of a meter socket such as a transformer or transfer station, for example only.

By example only, the bare ends 864 of the

conductors

860 and 862 are fixedly mounted, such as by crimping, in a wire crimp end 866 of

terminals

868 and 869. An aperture 870 in the opposite end of each terminal 868 and 869 receives the fastener 854 therethrough prior to the engagement of the fastener 852 to the jaw contact 812, the blade terminal 830 and the coupler 810 as described above.

FIG. 37 depicts another aspect of an electrical jaw blade assembly 900 which uses the identical jaw contact 812 and blade terminal 830 described above and shown in FIGS. 34-36. In this aspect, the jaw contact 812 and the blade terminal 830 are electrically connected by a fuse 902 to provide added protection to the socket adapter and utility service. Alternately, a shunt, solid state device, etc., could be used in place of the fuse 902.

The fuse 902 is of standard construction and has a general cylindrical body 904 with two outwardly extending, generally planar,

end tabs

906 and 908. An aperture, not shown, is formed in each of the

end tabs

906 and 908 and is alignable with the aperture 824 in the jaw contact 812 and the aperture 835 in the blade terminal 830. A fastener, such as a nut 910 with a threaded shank, is passed through the aligned apertures and locked in place by means of a washer 912, such as a lock washer or Belleville washer and a nut 914. The fasteners 910 securely hold the fuse 902 between the jaw contact 812 and the blade terminal 830 and enable the entire jaw blade and fuse assembly to be installed as a one piece, unitary structure.

In summary, there has been disclosed a unique one-piece coupler which couples a jaw contact and a blade terminal into a unitary one-piece construction for ease of installation, and reduced assembly steps and labor in mounting the jaw contact and blade terminal in a socket adapter. The coupler provides easy separate connections to the jaw contact and blade terminal for interconnection to a fuse, shunt, etc. In addition, the coupler is easily mountable in the housing of the socket adapter.

Claims

What is claimed is:

1. In a watthour meter socket adapter having a base wall and an annular sidewall extending from the base wall, at least one aperture in the base wall, the improvement comprising:

one separate jaw contact for receiving a blade term of an electrical apparatus;

one separate blade terminal for mounting through the one aperture in the base wall of the socket adapter;

the one separate jaw contact and the one separate blade terminal substantially co-axially aligned; and

a substantially axial coupler receiving the one jaw contact and the one blade terminal in a unitary, isolated, relationship.

2. The improvement of claim 1 wherein the coupler electrically isolates the jaw contact from the blade terminal.

3. The improvement of claim 1 wherein tile coupler comprises;

a first end portion for receiving the jaw contact and a second end portion for receiving the blade terminal.

4. In a watthour meter socket adapter having a base wall and an annular sidewall extending from the base wall at least one aperture in the base wall the improvement comprising:

one separate jaw contact for receiving a blade terminal of an electrical apparatus;

a coupler unitarily receiving the one jaw contact and the one blade terminal the coupler electrically isolates the jaw contact from the blade terminal; and

the coupler formed of a one-piece member of an electrically insulating material.

5. In a watthour meter socket adapter having a base wall and an annular sidewall extending from the base wall, at least one aperture in the base wall the improvement comprising;

a coupler having a first end portion for receiving the one jaw contact and a second end portion for receiving the one blade terminal in a unitary, isolated relationship; and

an engagement member carried on the first portion of the coupler for releasably engaging the jaw contact when the jaw contact is mounted in the first end portion of the coupler.

6. A coupler apparatus for use with a watthour meter socket adapter having a housing including a base wall and an Annular sidewall extending from the base wall, a plurality of apertures in the base wall for receiving individual electrical contacts, the electrical contacts including at least one separate jaw contact and at least one separate blade terminal mountable in one aperture in the base wall, the coupler apparatus comprising:

a jaw contact;

a blade terminal; and

a one piece body receiving the one jaw contact and the one blade terminal in a unitary assembly.

7. The coupler apparatus of claim 6 wherein the coupler is formed of an electrically insulating material.

8. The coupler apparatus of claim 6 further comprising:

the body having a first end portion for receiving the jaw contact and a second end portion for receiving the blade terminal.

9. The coupler apparatus of claim 8 further comprising:

an engagement member carried on the first end portion of the body for releasably engaging the jaw contact when the jaw contact is mounted in the first end portion of the body.

10. The coupler apparatus of claim 6 farther comprising:

the body having opposed first and second ends, the jaw contact and the blade terminal fixedly mounted on the first and second ends, respectively.

11. The coupler apparatus of claim 10 further comprising:

the jaw contact having a U-shaped channel portion.

12. The coupler apparatus of claim 11 wherein the jaw contact farther comprises:

spring clip fixedly mounted in the U-shaped channel portion.

13. The coupler apparatus of claim 12 wherein the U-shaped channel portion includes:

a central wall and two opposing sidewalls wending from the central wall, the spring clip mounted on the central wall.

14. The coupler apparatus of claim 10 wherein the blade terminal comprises:

a U-shaped channel with a central wall disposed between two sidewalks.

15. The coupler apparatus of claim 14 wherein:

an end portion of the central wall projects outwardly beyond the sidewalls to form a terminal portion of the blade terminal.

16. The coupler apparatus of claim 10 further comprising:

the jaw contact having a U-shaped channel portion;

the blade terminal having a U-shaped channel with a central wall disposed between two sidewalls; and

the body mountable between the U-shaped channels of the jaw contact and the blade terminal.